U.S. patent application number 10/071717 was filed with the patent office on 2002-05-23 for carton blank, carton and method.
Invention is credited to Conatser, Robert L., Kastanek, Raymond S., Walsh, Joseph C..
Application Number | 20020060240 10/071717 |
Document ID | / |
Family ID | 56290202 |
Filed Date | 2002-05-23 |
United States Patent
Application |
20020060240 |
Kind Code |
A1 |
Walsh, Joseph C. ; et
al. |
May 23, 2002 |
Carton blank, carton and method
Abstract
Disclosed herein is a carton and a carton blank having a first
sidewall panel, a second sidewall panel joined to the first
sidewall panel by a first fold line and a third sidewall panel
joined to the first sidewall panel by a second fold line. The
carton and carton blank may further have a first top panel joined
to the first sidewall panel by a third fold line, a second top
panel joined to the second sidewall panel by a fourth fold line and
a third top panel joined to the third sidewall panel by a fifth
fold line. The second top panel may have a sixth fold line
extending in a direction substantially perpendicular to the fourth
fold line, a first score line intersecting the sixth fold line and
wherein the first score line at least partially defines a first tab
portion extending from the sixth fold line in a first direction.
The third top panel may further include a seventh fold line
extending in a direction substantially perpendicular to the fifth
fold line, a second score line intersecting the seventh fold line
and wherein the second score line at least partially defines a
second tab portion extending from the seventh fold line in a second
direction opposite the first direction. Also disclosed herein is a
method of retaining a flip top lid in an open position.
Inventors: |
Walsh, Joseph C.; (Boulder,
CO) ; Conatser, Robert L.; (Longmont, CO) ;
Kastanek, Raymond S.; (Longmont, CO) |
Correspondence
Address: |
Michael A. Goodwin, Esq.
Klaas, Law O'Meara & Malkin, P.C.
Suite 2225
1999 Broadway
Denver
CO
80202
US
|
Family ID: |
56290202 |
Appl. No.: |
10/071717 |
Filed: |
February 8, 2002 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
10071717 |
Feb 8, 2002 |
|
|
|
09972575 |
Oct 5, 2001 |
|
|
|
09972575 |
Oct 5, 2001 |
|
|
|
09607197 |
Jun 28, 2000 |
|
|
|
60244716 |
Oct 30, 2000 |
|
|
|
Current U.S.
Class: |
229/117.27 ;
229/231 |
Current CPC
Class: |
B65D 5/6623
20130101 |
Class at
Publication: |
229/117.27 ;
229/231 |
International
Class: |
B65D 005/56; B65D
017/32 |
Claims
What is claimed is:
1. A carton blank comprising: at least one first sidewall panel; at
least one second sidewall panel joined to said at least one first
sidewall panel by a first fold line; at least one third sidewall
panel joined to said at least one first sidewall panel by a second
fold line; at least one first top panel joined to said at least one
first sidewall panel by at least one third fold line; at least one
second top panel joined to said at least one second sidewall panel
by at least one fourth fold line; at least one third top panel
joined to said at least one third sidewall panel by at least one
fifth fold line; said at least one second top panel further
comprising: at least one sixth fold line extending in a direction
substantially perpendicular to said at least one fourth fold line;
at least one first score line intersecting said at least one sixth
fold line; and wherein said at least one first score line at least
partially defines at least one first tab portion extending from
said at least one sixth fold line in a first direction; said at
least one third top panel further comprising: at least one seventh
fold line extending in a direction substantially perpendicular to
said at least one fifth fold line; at least one second score line
intersecting said at least one seventh fold line; and wherein said
at least one second score line at least partially defines at least
one second tab portion extending from said at least one seventh
fold line in a second direction opposite said first direction.
2. The carton blank of claim 1 and further wherein said at least
one sixth fold line and said at least one seventh fold line are
located so that they are in a superposed relationship when said
carton blank is erected into a carton and said at least one third
top panel is superposed over said at least one second top
panel.
3. The carton blank of claim 1 and further wherein said at least
one sixth fold line comprises at least a pair of spaced apart sixth
fold lines.
4. The carton blank of claim 3 and further wherein said at least
one first score line extends between said at least a pair of spaced
apart sixth fold lines.
5. The carton blank of claim 1 and further wherein said at least
one first score line comprises an arcuate shaped score line.
6. The carton blank of claim 1 and further comprising: a first
inner layer located opposite at least portions of said first,
second and third sidewall panels; said first inner layer comprising
at least a first partial sidewall panel, a second partial sidewall
panel and a third partial sidewall panel, said first partial
sidewall panel being joined to said second and third partial
sidewall panels by opposite fold lines; said opposite fold lines
defining a first partial sidewall panel width extending
therebetween; said first fold line and said second fold line
defining a first sidewall panel width extending therebetween; said
first sidewall panel width and said first partial sidewall panel
width being substantially the same; said first inner layer having
an upper edge portion and a lower edge portion; at least a portion
of said first partial sidewall panel being secured to at least a
portion of said first sidewall panel; said upper edge portion being
located adjacent to but spaced from at least a portion of said
third, fourth and fifth fold lines.
7. The carton blank of claim 6 and further comprising: a second
inner layer comprising a sheet of a relatively flexible fluid
impervious material; at least a portion of said second inner layer
being secured to at least a portion of said first sidewall panel;
at least a portion of said second inner layer being secured to at
least a portion of said first inner layer;
8. The carton blank of claim 7 wherein said second inner layer
comprises a weakened portion located adjacent to but spaced from
said upper edge portion of said first inner layer.
9. The carton blank of claim 6 wherein said first inner layer
comprises a generally rectangular sheet of a relatively rigid
material.
10. A dispensing carton comprising: at least one first sidewall
panel; at least one second sidewall panel joined to said at least
one first sidewall panel by a first fold line; at least one third
sidewall panel joined to said at least one first sidewall panel by
a second fold line; at least one first top panel joined to said at
least one first sidewall panel by at least one third fold line; at
least one second top panel joined to said at least one second
sidewall panel by at least one fourth fold line; at least one third
top panel joined to said at least one third sidewall panel by at
least one fifth fold line; said at least one second top panel
further comprising: at least one sixth fold line extending in a
direction substantially perpendicular to said at least one fourth
fold line; at least one first score line intersecting said at least
one sixth fold line; and wherein said at least one first score line
at least partially defines at least one first tab portion extending
from said at least one sixth fold line in a first direction; said
at least one third top panel further comprising: at least one
seventh fold line extending in a direction substantially
perpendicular to said at least one fifth fold line; at least one
second score line intersecting said at least one seventh fold line;
and wherein said at least one second score line at least partially
defines at least one second tab portion extending from said at
least one seventh fold line in a second direction opposite said
first direction.
11. The dispensing carton of claim 10 and further wherein said at
least one sixth fold line is superposed with said at least one
seventh fold line.
12. The dispensing carton of claim 10 and further wherein said at
least one sixth fold line comprises at least a pair of oppositely
spaced apart sixth fold lines.
13. The dispensing carton of claim 12 and further wherein said at
least one first score line extends between said at least a pair of
oppositely spaced apart sixth fold lines.
14. The dispensing carton of claim 10 and further wherein said at
least one first score line comprises an arcuate shaped score
line.
15. The dispensing carton of claim 10 and further comprising: a
first inner layer located opposite portions of said first, second
and third sidewall panels; said first inner layer comprising at
least a first partial sidewall panel, a second partial sidewall
panel and a third partial sidewall panel, said first partial
sidewall panel being joined to said second and third partial
sidewall panels by opposite fold lines; said opposite fold lines
defining a first partial sidewall width extending therebetween;
said first fold line and said second fold line defining a first
sidewall panel width extending therebetween; said first sidewall
panel width and said first partial sidewall panel width being
substantially the same; said first inner layer having an upper edge
portion and a lower edge portion; at least a portion of said first
partial sidewall panel adjacent to said lower edge portion being
secured to at least a portion of said first sidewall panel; said
upper edge portion being located adjacent to but spaced from said
third, fourth and fifth fold lines.
16. The dispensing carton of claim 15 and further comprising: a
second inner layer comprising a generally rectangular sheet of a
relatively flexible fluid impervious material; at least a portion
of said second inner layer being secured to at least a portion of
said outer layer; at least a portion of said second inner layer
being secured to at least a portion of said first inner layer
17. The dispensing carton of claim 16 wherein said second inner
layer having a weakened portion located adjacent to but spaced from
said upper edge portion of said first inner layer.
18. The carton blank of claim 15 wherein said first inner layer
comprises a generally rectangular sheet of a relatively rigid
material.
19. A method comprising: providing a container comprising: at least
one first sidewall panel; at least one second sidewall panel; at
least one third sidewall panel joined to said at least one first
sidewall panel by at least one first fold line and to said at least
one second sidewall panel by at least one second fold line; at
least one first top panel joined to said at least one first
sidewall panel by at least one third fold line; at least one second
top panel joined to said at least one second sidewall panel by at
least one fourth fold line; said at least one first top panel
further comprising at least one fifth fold line extending in a
direction substantially perpendicular to said at least one third
fold line; said at least one second top panel further comprising at
least one sixth fold line extending in a direction substantially
perpendicular to said at least one fourth fold line; said at least
one fifth fold line and said at least one sixth fold line being in
superposed relationship, thereby forming a hinge; at least one
first score line formed in said at least one first sidewall panel,
said at least one first score line extending from said at least one
third fold line to said at least one first fold line; at least one
second score line formed in said at least one second sidewall
panel, said at least one second score line extending from said at
least one fourth fold line to said at least one second fold line;
at least one third score line formed in said at least one third
sidewall panel, said at least one third score line extending from
said at least one first score line to said at least one second
score line; said at least one first, at least one second and at
least one third score lines together at least partially defining a
flip top lid in said container; moving said flip top lid from a
closed position to an open position by rotating said flip top lid
about said hinge; and releasably retaining said flip top lid in
said open position.
20. The method of claim 19 wherein: said at least one fifth fold
line comprises at least a pair of spaced fifth fold lines.
21. The method of claim 20 wherein: said at least one first top
panel further comprises at least one fourth score line extending
between said at least a pair of spaced fifth fold lines; and said
at least one fourth score line at least partially defines at least
one first tab portion in said at least one first top panel.
22. The method of claim 21 wherein: said at least one sixth fold
line comprises at least a pair of spaced sixth fold lines; said at
least one second top panel further comprises at least one fifth
score line extending between said at least a pair of spaced sixth
fold lines; and said at least one fifth score line at least
partially defines at least one second tab portion in said at least
one second top panel.
23. The method of claim 22 wherein said releasably retaining said
flip top lid in said open position comprises contacting said at
least one first tab portion with said at least one second tab
portion.
24. The method of claim 22 wherein: said at least one first tab
portion extends from said at least a pair of spaced fifth fold
lines; said at least one second tab portion extends in a second
direction from said at least a pair of spaced sixth fold lines; and
said first direction is opposite said second direction.
Description
[0001] This application is a continuation of application Ser. No.
09/972,575 filed Oct. 5, 2001, for CARTON BLANK, CARTON AND METHOD
OF FORMING THE CARTON of Walsh et al. which is a
continuation-in-part of U.S. patent application Ser. No. 09/607,197
filed Jun. 28, 2000, for CARTON BLANK, CARTON AND METHOD OF FORMING
THE CARTON of Walsh et al., and which claims the benefit of U.S.
provisional patent application Serial No. 60/244,716 filed Oct. 30,
2000, for CARTON BLANK, CARTON AND METHOD OF FORMING THE CARTON of
Walsh et al., all of which are hereby incorporated by reference for
all that is disclosed therein.
FIELD
[0002] The disclosure herein is directed generally to a carton
blank, a carton that may be formed therefrom and related
methods.
BACKGROUND
[0003] Products are commonly packaged in cartons which may, for
example, be formed from a paperboard material. Examples of such
cartons include cereal boxes, milk cartons, butter and margarine
boxes and beer and soft drink secondary packaging (e.g., cartons
enclosing a plurality of beer or soft drink cans or bottles).
[0004] Some cartons have opening features in order to provide
access to the contents of the carton. Such opening features may,
for example, take the form of pour spouts, tear panels or flip top
lids.
[0005] In order to protect moisture sensitive materials in a
carton, there have been many kinds of fluid impervious cartons
developed to protect such moisture sensitive materials from
deleterious elements such as the humidity in the air. The vast
majority of these leakproof cartons have an outer layer formed from
a relatively rigid material and an inner layer formed from a
relatively flexible fluid impervious material to provide the
moisture protection. When it is desired to remove an amount of the
material in the carton, it is generally necessary to open both the
outer and inner layers.
SUMMARY
[0006] Disclosed herein is a carton and a carton blank having a
first sidewall panel, a second sidewall panel joined to the first
sidewall panel by a first fold line and a third sidewall panel
joined to the first sidewall panel by a second fold line. The
carton and carton blank may further have a first top panel joined
to the first sidewall panel by a third fold line, a second top
panel joined to the second sidewall panel by a fourth fold line and
a third top panel joined to the third sidewall panel by a fifth
fold line. The second top panel may have a sixth fold line
extending in a direction substantially perpendicular to the fourth
fold line, a first score line intersecting the sixth fold line and
wherein the first score line at least partially defines a first tab
portion extending from the sixth fold line in a first direction.
The third top panel may further include a seventh fold line
extending in a direction substantially perpendicular to the fifth
fold line, a second score line intersecting the seventh fold line
and wherein the second score line at least partially defines a
second tab portion extending from the seventh fold line in a second
direction opposite the first direction.
[0007] Also disclosed herein is a method of retaining a flip top
lid in an open position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Illustrative and presently preferred embodiments are
illustrated in the accompanying drawings in which:
[0009] FIG. 1 is a top plan view of the outer surface of a carton
blank;
[0010] FIG. 2 is a top plan view of the inner surface of a carton
blank with parts broken away;
[0011] FIGS. 3-5 are top plan views illustrating different steps in
the formation of the top portion of a carton from a carton
blank;
[0012] FIG. 6 is a enlarged portion of FIG. 5 illustrating one of
the weakened portions;
[0013] FIG. 7 is a perspective view of a closed carton;
[0014] FIG. 8 is a perspective view of a partially opened carton;
and
[0015] FIG. 9 is an enlarged perspective view of a opened carton
wherein the flip top lid is being retained in an opened
position;
[0016] FIG. 10 is a schematic elevational view with parts in
section of a portion of the top of a carton prior to the formation
of the opening therein;
[0017] FIG. 11 is a schematic elevational view with parts in
section and wherein the flip top lid has been formed and is
partially opened; and
[0018] FIG. 12 is a schematic elevational view with parts in
section and wherein the flip top lid is being held in the opened
position.
[0019] FIG. 13 is a partial perspective view of a closed carton
having a stay closed feature.
[0020] FIG. 14 is a plan view of an insert member forming a part of
the carton of FIG. 13.
[0021] FIG. 15 is a partial cross-sectional view taken along the
line 15-15 in FIG. 13.
[0022] FIG. 16 is a partial cross-sectional view similar to FIG.
15, but showing the carton in a partially open condition.
[0023] FIG. 17 is a partial cross-sectional view similar to FIGS.
15 and 16, but showing the carton in a further open condition.
[0024] FIG. 18 is a partial cross-sectional view similar to FIGS.
15-17, but showing the carton after it has been re-closed.
[0025] FIG. 19 is a plan view of an insert member used in a carton
having an alternative stay closed feature.
[0026] FIG. 20 is a partial cross-sectional view, similar to FIGS.
15-18, but showing a carton including the insert member of FIG. 19
in a partially open condition.
[0027] FIG. 21 is a partial cross-sectional view similar to FIG.
20, but showing the carton in a further open condition.
[0028] FIG. 22 is a partial cross-sectional view similar to FIGS.
20 and 21, but showing the carton after it has been re-closed.
Detailed Description
[0029] In FIG. 1, there is illustrated the outer surface of a
carton blank 2. The carton blank 2 has an outer layer which
comprises a generally rectangular sheet of a relatively rigid
material such as paperboard, a composite materials comprising a
plastic film laminated to paperboard or any other conventional
material used in forming cartons and has a plurality of integral
sidewall panels 4, 6, 8 and 10 which are joined together by fold
lines 12, 14 and 16 and a glue tab panel 18 integral with the
sidewall panel 10 and joined thereto by a fold line 20. A plurality
of bottom panels 22, 24, 26 and 28 are integral with the sidewall
panels 4, 6, 8 and 10 and are joined thereto by fold lines 30, 32,
34 and 36 and are separated from each other by cut lines 38, 40 and
42. A plurality of top panels 44, 46, 48 and 50 are integral with
the sidewall panels 4, 6, 8 and 10 and are joined thereto by fold
lines 52, 54, 56 and 58 and are separated from each other by cut
lines 60, 62, 64 and 66. The cut lines 60 and 62 are spaced apart
to form an opening 68 therebetween. The top panel 44 has a pair of
spaced apart opposite fold lines 70 and 72 and an arcuate shaped
perforated line 74 which, when broken, forms a tab portion 76. The
top panel 48 has a pair of spaced apart opposite fold lines 78 and
80 and an arcuate shaped perforated line 82 which, when broken,
forms a tab portion 84. A first weakened portion 86 has a first end
point 88 in the fold line 56 and a second end point 90 in the fold
line 14. A second weakened portion 92 has a first end point 94 in
the fold line 52 and a second end point 96 in the fold line 12. A
third weakened portion 98 extends between the second end points 90
and 96 and is shaped as a frustum of a V. As illustrated in FIG. 1,
the weakened portions 86, 92 and 98 form portions 4a, 6a and 8a in
the sidewall panels 4, 6 and 8. An opening tab 100 is formed in the
sidewall panel 6 by a perforated line 102 and extensions 104 and
106 thereof which extensions 104 and 106 are parallel to but spaced
slightly from portions of the fold lines 12 and 14. A tab portion
108 extends from a fold line 110 for purposes described below.
[0030] In FIG. 2, there is illustrated the inner surface of a
carton blank 2. The portions illustrated in FIG. 2 that correspond
to FIG. 1 have been identified with the same reference numerals. A
first inner layer comprising a generally rectangularly shaped
insert 120 has a partial sidewall panel 122 superposed over a
portion of the sidewall panel 6; a partial sidewall panel 124
superposed over a portion of the sidewall panel 4 and a partial
sidewall panel 126 superposed over a portion of the sidewall panel
8. The partial sidewall panel 124 and the partial sidewall panel
126 are integral with the partial sidewall panel 122 and are joined
thereto by the fold lines 128 and 130 which are substantially
superposed over portions of the fold lines 12 and 14. The insert
120 has an upper edge 132 that is spaced slightly from the fold
line 54 and portions of the fold lines 52 and 56 and a lower edge
134. The portion of the partial sidewall panel 122 adjacent to the
lower edge 134 is secured to the opposite facing inner surface of
the sidewall panel 6 by a suitable adhesive 136. The first inner
layer or insert 120 is preferably formed from the same type of
material as the outer layer.
[0031] A second inner layer of the carton blank 2 comprises a
generally rectangular sheet 140 of a fluid impervious material
comprising a central body portion 142 that is superposed over at
least portions of the portions of the sidewall panels 4, 6, 8 and
10 located between but spaced slightly from the fold lines 52, 54,
56 and 58 and the fold lines 30, 32, 34 and 36 and a corresponding
portion of the glue tab panel 18 and all of the insert 120. The
generally rectangular sheet 140 is preferably formed from a plastic
material, such as polyethylene, a kraft paper covered with
polyethylene or other materials having similar characteristics. At
least portions of the central body portion 142 are secured to
facing portions of the insert 120 and the sidewall panels 4, 6, 8
and 10 and the glue tab panel 18. The generally rectangular sheet
140 has a top portion 144 that extends from the central body
portion 142 and is superposed over at least portions of the top
panels 44, 46, 48 and 50 and the glue tab panel 18. In one example
of a preferred embodiment, the top portion 144 is superposed over
and secured to an elongated strip 146 of a relatively flexible
material, such as a kraft paper or other materials having similar
characteristics. The generally rectangular sheet 140 had a bottom
portion 148 that extends from the central body portion 142 and is
superposed over at least portions of the bottom panels 22, 24, 26
and 28 and the glue tab panel 18. The bottom portion 148 is
superposed over and secured to a strip 150 of a relatively flexible
material as described above. In some instances, the strips 146 and
150 may be omitted so that the top 144 and bottom 148 portions
comprise only portions of the sheet 140 of a fluid impervious
material. As illustrated in FIG. 2, two of the edges of the
generally rectangular sheet 140 are located in alignment with the
edge of the glue tab panel 18 and the edge of the sidewall panel 4
but in some instances such edges may be offset a desired
distance.
[0032] FIGS. 3-5 illustrate steps in forming a closed and sealed
end for a carton formed from the carton blank 2 described in
relation to FIGS. 1 and 2. The sidewall panels 4, 6, 8 and 10 are
folded around the fold lines 12, 14 and 16 and secured together by
a suitable arrangement between the glue tab panel 18 and a portion
of the sidewall panel 4 or portions of the sheet 140 associated
with the structures to form an open ended structure (not shown).
The bottom panels 22, 24, 26 and 28 and the bottom portion 148 with
or without the strip 150 have been folded and secured together to
form a closed fluid impervious bottom end for the carton. The
carton is then filled with a desirable material and the top portion
144 with or without the strip 146 has been folded and sealed
together to form a closed fin joint. The fin joint is formed from
the top portion 144 that extends upwardly from a common plane
formed by the fold lines 52, 54, 56 and 58 and comprises portions
of the generally rectangular sheet 140 that extend from the
sidewall panels 4, 6, 8 and 10 to form an open top portion. The
portions of the generally rectangular sheet adjacent to the open
top portion are secured together to form two sealed together layers
having a central section 160 and two opposite end sections 162 and
164. The extensions of the top portion 144 from the sidewall panels
4 and 8 are also formed into generally horizontal portions 166 and
168 that lie in a common plane generally parallel to the
above-described common plane. The generally horizontal portions 166
and 168 comprise a single thickness of the generally rectangular
sheet 140. The extensions of the top portion 144 from the sidewall
panels 6 and 10 and the glue tab panel 18 are also formed into
triangular end sections 152 and 154 illustrated in FIGS. 3 and 4 by
two reference numerals which comprise two thicknesses of the
generally rectangular sheet 140. The triangular end sections 152
and 154 also lie in a plane parallel to the common planes described
above. As illustrated in FIG. 3, the central section 160 and the
end sections 162 and 164 of the fin joint have been folded over so
that they lie substantially in the common plane formed by the fold
lines 52, 54, 56 and 58. Therefore, the fin joint has a central
section comprising the central section 160 and the portions 166 and
168 and two opposite end sections comprising the end sections 162
and 164 and the triangular portions 152 and 154. In FIG. 4, the top
panel 44 is folded around fold line 52 until it is superposed over
a major portion of the central section comprising the central body
portion 160 and the portions 166 and 168 but is not secured
thereto. The top panel 50 is then folded around fold line 58 so
that it is superposed over a portion of the top panel 44 and the
end sections 154 and 164 are sandwiched in between. These portions
are not adhesively secured together. The top panel 46, preferably
at the same time, is folded around fold line 54 so that it is
superposed over a portion of the top panel 44 and the open portion
formed by the cut line 60 and the end sections 154 and 162 are
sandwiched in between. These portions are not adhesively secured
together. The structure prior to folding over the top panel 46 is
illustrated in FIG. 5. The top panel 48 is then folded around fold
line 56 until it is superposed over the top panels 44 and 50 and
the central portion of the top panel 44. At least the facing
portions of the top panels 48, 46, 50 and 44 are secured together.
The fold lines 78 and 80 are superposed over the fold lines 70 and
72 and the tab portions 76 and 84 extend in opposite
directions.
[0033] In FIG. 6, there is illustrated part of the structures for
forming the flip top lid for the carton as described below. The
generally rectangular sheet 140 is superposed over the inner
surface of the outer layer of the carton blank 2 of FIG. 2 and is
secured thereto by a suitable adhesive illustrated by the dotted
portion. The generally rectangular sheet 140 also is superposed
over the generally rectangular first inner layer or insert 120. A
weakened portion 170 having end portions 172 and 174 is formed in
the generally rectangular sheet 140. In an exemplary preferred
embodiment, the length of the weakened portion 170 between the end
portions 172 and 174 is less than the distance between the fold
lines 72 and 80 as illustrated in FIG. 6. The weakened portion 170
is surrounded by an adhesive, illustrated by the more heavily
dotted area, to preserve the fluid tightness between the portion of
the generally rectangular sheet 140 and the first inner layer or
insert 120. The weakened portion 170 may comprise a cut line or a
perforated line and may be formed using a heated cutting apparatus
(not shown) so that, as the weakened portion 170 is made, the
portions of the generally rectangular sheet 140 surrounding the
weakened portion 170 are secured to the first inner layer or insert
120. In another exemplary embodiment, a coating of a suitable
adhesive, such as a conventional hot or cold melt adhesive, may be
used as long as the fluid impervious characteristic of the second
inner layer or generally rectangular sheet 140 is maintained. The
weakened portion 164 is preferably located as close as possible to
the upper edge 132 of the first inner layer or insert 120 for
purposes described below. The location of the weakened portion 164
as shown in FIG. 6 is for illustration purposes only.
[0034] A carton 180 formed from the carton blank 2 of FIGS. 1 and 2
and having its top portion formed as illustrated in FIGS. 3-5 is
illustrated in FIGS. 7-9. In FIG. 7, the carton 180 is one that has
been filled with the desired material as described above. In FIG.
8, the flip top lid 182 having portions 4a, 6a and 8a secured from
the sidewall panels 4, 6 and 8 and the tab portion 108 has been
partially opened. As illustrated in FIG. 8, the opening tab 100 has
been removed by applying a force thereto at the fold line 14 and
severing it along the perforated lines 104, 102, 98 and 106.
Another force has been applied to the tab 108 to sever the outer
layer along the perforated lines 86 and 92. At the same time, the
force separates the weakened portion 170 since the portion 162
located between the folded over top panel 46 and the top panel 44
applies the force to the weakened portion 170. The tab portion 84
has separated along the score line 82 as the flip top lid 182 moves
upwardly in a pivoted manner through an arcuate path defined by the
fold lines 78 and 80. The pivotal movement of the flip top lid 182
is continued until the outer surface (not numbered) of the tab
portion 84 faces the outer surface (not numbered) of the tab
portion 76. This pivotal movement is generally about 120 degrees.
In FIG. 9, the flip top lid 182 is held in an opened position by
the cooperation between outer surfaces of the tab portions 76 and
84 which generally is about 90 degrees so that an amount of the
desired material may be removed from the carton 180. After an
amount of the desired material has been removed from the carton
180, a force is applied to the flip top lid 182 to return it
generally to the position illustrated in FIG. 7 but with the
opening tab 100 removed.
[0035] FIGS. 10-12 illustrate the location of the various
components at different times during the formation of the opening
in the carton 180. In FIG. 10, the carton 180 has not been opened.
In FIG. 11, the carton 180 has been partially opened. In FIG. 12,
the carton 180 has been fully opened and the flip top lid 182 is
being held in an opened position so that an amount of the desired
material may be removed from the carton 180. In FIG. 12, the flip
top lid 182 has been moved to a partially opened position. Part of
the weakened portion 170 has been severed. The portion of the
weakened portion 170 between the panels 6 and 6a and part of the
weakened portion 170 between the panels 4 and 4a and 8 and 8a has
been separated. Since the end sections of the fin joint are
sandwiched between portions of the top panels 44 and 46, a force is
applied to the end sections 152 and 162 and portions of the
portions 166 and 168 of the fin joint to pull these portions
downwardly through the opening 68 formed by the cut line 60. In
FIG. 12, the weakened portion 170 has been completely severed and a
large portion of the end sections 152 and 162 and the portions 166
and 168 of the fin joint have been moved through the opening 68. As
described above, the contact between the outer surfaces of the tab
portions 76 and 84 holds the flip top lid 182 in the opened
position so that an amount of the desired material may be removed
from the carton 180. In FIGS. 10-12, the strips 146 and 150 of a
relatively flexible material are not shown but would be included in
an exemplary preferred embodiment.
[0036] FIGS. 13-18 illustrate a carton 280. The carton 280 may be
substantially identical to the carton 80 previously described with
respect to FIGS. 1-12, except that the carton 280 is provided with
a flip top lid 382 having a feature to allow the lid to be securely
re-closed after initial opening, as will be described in further
detail below. Because the carton 280 is similar in many aspects to
the carton 80, the same reference numerals are used in FIGS. 13-18
to refer to like features illustrated in FIGS. 1-12.
[0037] As noted above, the carton 280 may be formed in a
substantially identical manner to that described with respect to
the carton 80 previously described with respect to FIGS. 1-12. With
reference to FIG. 13, the carton 280 may, however, include an
insert member 320 which is modified relative to the insert member
120 previously described with respect to the carton 80. FIG. 14
illustrates the modified insert member 320 in further detail.
[0038] Referring now to FIG. 14, the insert member 320 may have a
partial sidewall panel 322; a partial sidewall panel 324 and a
partial sidewall panel 326. The partial sidewall panel 324 and the
partial sidewall panel 326 may be integral with the partial
sidewall panel 322 and may be joined thereto by the fold lines 328
and 330. The insert member 320 has an upper edge 332. The insert
member 320 may, for example, be formed from the same material as
previously described with respect to the insert member 120. A
cutout portion 340 may be provided in the partial sidewall panel
322 of the insert member 320 as shown. The cutout portion 340 may
generally be defined by an upper cut line 342 and a lower cut line
344. The cut lines 342, 344 may extend completely through the
material forming the insert member 320 such that, together, the cut
lines 342, 344 will form an opening 356 in the insert member 320
after the cutout portion 340 is removed, as will be described in
further detail herein. A pair of uncut areas may be located between
the cut lines 342 and 344 forming retention tabs 346 and 348. The
retention tabs 346, 348 serve to retain the cutout portion to the
remainder of the insert member 320 during manufacture of the carton
280 in a manner as will be described in further detail herein.
[0039] With continued reference to FIG. 14, a score line 350 may be
provided as shown, dividing the cutout portion 340 into an upper
(as viewed in FIG. 14) hinge portion 352 and a lower stationary
portion 354. The cutout portion 340 may, for example, have a height
"a" of about 1.0 inch and a width "b" of about 1.5 inches and may,
for example, be generally elliptical is shape. The score line 350
may, for example, be located a distance "c" of about 0.6 inch above
the lower edge of the cutout 340. The lower edge of the cutout 340,
in turn, may be located a distance "d" of about 1.85 inch below the
upper edge 332 of the insert member 320.
[0040] The insert member 320 may be assembled into the carton blank
2 in substantially the same manner as previously described with
respect to the insert member 120, see FIG. 2. When assembling the
insert member 320, however, adhesive 360, FIG. 15, may be supplied
between the insert member stationary portion 354, FIG. 14, and the
carton blank sidewall panel 6, FIG. 2. In addition, although the
rectangular sheet 140 may be secured to the insert member 320
around the periphery of the cutout portion 340, the sheet 140 is
not secured to the cutout portion 340 itself. Securing the
rectangular sheet 140 to the insert member 320 and to the remainder
of the carton blank 2 may be accomplished using a conventional glue
or by any other conventional attachment mechanism.
[0041] After the insert member 320 has been attached to the carton
blank 2, as described above, the carton blank may be erected into
the carton 280, as illustrated in FIG. 13. FIG. 15 is a
cross-sectional view of the carton 280, taken along the line 15-15
of FIG. 13. FIGS. 13 and 15 both illustrate the carton 280 before
the flip top lid 382 has initially been opened. FIGS. 16-18
illustrate a sequence of operations through which the flip top lid
382 is opened and then re-closed.
[0042] The carton 280 may be initially opened in generally the same
manner as the carton 80, previously described. Specifically, to
initially open the carton 280, the opening tab 100, FIGS. 13 and
15, may be removed. The tab 108 may then be pulled upwardly,
severing the outer layer of the carton 280 along the perforated
lines 86 and 92, to the position illustrated in FIG. 16. Referring
now to FIG. 16, it can be seen that the movement described above
has also caused the cutout portion 340 to separate from the insert
member 320, due to the adhesive 360 located between the flip top
lid 382 and the stationary portion 354 of the cutout portion 340.
Specifically, with reference to FIG. 14, the upward movement of the
flip top lid 382 has caused the retention tabs 346 and 348 to tear,
thus allowing the cutout portion 340 to completely separate from
the remainder of the insert member 320. Referring again to FIG. 16,
the upward movement of the flip top lid 382 also causes the hinge
portion 352 of the cutout portion 340 to bend about the score line
350, due to the interaction between the hinge portion 352 and the
upper edge of the opening 356. As can be appreciated from FIG. 16,
although separation of the cutout portion 340 forms the opening 356
through the insert member 320, the sheet 140 still spans the
opening 356.
[0043] FIG. 17 illustrates the flip top lid 382 in a further opened
condition. Referring to FIG. 17, it can be seen that the hinge
portion 352 is completely disengaged from the opening 356, but
still maintains a nonaligned orientation with respect to the
stationary portion 354. The hinge portion 352 is biased toward this
nonaligned orientation due to the score line 350 and the bending
action imposed on the hinge portion 352 during opening of the lid
382, as illustrated in FIG. 16.
[0044] After the desired amount of product has been dispensed from
the open carton 280, the flip top lid 382 may be re-closed. This
re-closed condition is illustrated in FIG. 18. As can be seen from
FIG. 18, when the flip top lid is returned to its closed position,
the hinge portion 352 will engage beneath the upper edge of the
opening 356. This engagement, in turn, causes the lid 382 to resist
reopening and, thus, tends to maintain the lid in its closed
condition, as illustrated in FIG. 18.
[0045] When it is desired to reopen the flip top lid 382, e.g., to
dispense further product from the container 280, the tab 108 may
again be pulled upwardly, thus causing the flip top lid 382 to once
again move through the sequence illustrated in FIGS. 16 and 17. As
can be appreciated from the above, the cutout portion 340 serves to
maintain the flip top lid 382 in its closed position after the lid
has initially been opened but allows the lid to be reopened when
desired.
[0046] It is noted that, in addition to holding the lid in its
closed position, the stay-closed feature described above also
results in an audible "click" when the lid reaches its closed
position. This click is caused when, as the lid is moving
downwardly to its closed position, the hinge portion 352 springs
into the opening 356. This feature is beneficial in that it
provides a user of the carton 280 with an audible signal indicating
that the lid has reached its fully closed position. The audible
click discussed above is caused, in part, by the hinge portion 352
springing past the edge of the opening 356. The volume of the
audible click is also, however, enhanced by the hinge portion 352
forcefully contacting the sheet 140, as illustrated in FIG. 18.
Accordingly, the existence of the sheet 140 in the vicinity of the
opening 356 enhances the audible signal provided.
[0047] The existence of the sheet 140 in the vicinity of the
opening 356 is also advantageous in that it seals the opening 356
and, thus, prevents product housed withing the carton 280 from
exiting the carton through the opening 356. The existence of the
sheet 140 is further advantageous in that it prevents the hinge
portion 352 from penetrating too far into the opening 356, see FIG.
16. In some situations, such excessive penetration by the hinge
portion 352 may interfere with proper reopening of the flip top lid
382. As can be appreciated with reference to FIG. 16, in limiting
the penetration by the hinge portion 352, the sheet 140 imposes a
resilient force (in the direction of the arrow 362) on the flip top
lid 382. This resilient force causes the flip top lid 382 to be
biased toward its closed position until the hinge portion 352
disengages from the opening 356 during opening of the flip top lid
382. This biasing of the flip top lid, in turn, causes the flip top
lid to tend to remain in its closed position until a sufficient
opening force is applied and, thus, serves to resist accidental
opening of the flip top lid 382.
[0048] Although, as described above, the existence of the sheet 140
is beneficial in many respects, the carton 280 may, alternatively,
be manufactured without the sheet 140. In this case, a relatively
small section of material may be provided in order to cover the
opening 356. This small section of material may be attached, e.g.,
by gluing, to the partial sidewall panel 322 of the insert member
320, FIG. 14, in the vicinity of the opening 356. The small section
of material may, for example, be formed from the same material as
the sheet 140.
[0049] The stay closed feature described above is extremely
advantageous in that it is easy to manufacture. Specifically, the
use of the cutout 340 does not require that any extra folds be
provided in the insert member 320. Such folds add complexity when
erecting a carton and it is, thus, desirable to minimize them.
Referring, for example, to FIG. 17, it can be seen that the hinge
portion 352 is partially folded about the score line 350. In other
words, the hinge portion 352 is non-aligned with the stationary
portion 354. This non-aligned configuration enables the hinge
portion 352 to spring into the opening 356 when the flip top lid
382 is re-closed (see FIG. 18) and, thus, is important to proper
operation of the stay closed feature. As can be appreciated with
respect to FIGS. 15 and 16, this folding of the hinge portion 352
is caused by the opening of the flip top lid 382. In other words,
before the flip top lid is initially opened (FIG. 15), the hinge
portion 352 is not folded about the score line 350. Rather, the
opening force supplied to the flip top lid 382 by a user causes the
folding to occur. Accordingly, the fold does not have to be formed
on the production line for forming the carton 280. This, in turn,
simplifies the carton forming process.
[0050] The described stay closed feature is further advantageous in
that no additional material is required in its formation.
Specifically, as described above, the cutout portion 340, which
includes the hinge portion 352, is removed from an existing portion
of the insert member 320. Accordingly, no additional material is
required to form the cutout portion 340. Additionally, because the
cutout portion 340 is located on the inside of the flip top lid
panel 6a, it is never readily visible to a consumer of the product
packaged within the carton 280. Accordingly, the design of the stay
closed feature described herein facilitates the aesthetic
appearance of the carton.
[0051] It is noted that, although the stay-closed feature has been
described in conjunction with the stay open feature of FIGS. 1-12
for illustration purposes, it is to be understood that either the
stay closed feature or the stay open feature could, alternatively,
be used independently of each other. It is further noted that,
although, for illustration purposes, the stay closed feature is
illustrated as being elliptical in shape, it could, alternatively,
be any other shape, such as rectangular or round.
[0052] FIGS. 19-22 illustrate an alternative embodiment of the stay
closed feature in which the hinge portion remains attached to the
insert member. Referring first to FIG. 19, an insert member 420 may
be provided which is similar to the insert member 320 previously
described with respect to FIGS. 13-18. The insert member 420 may
have a partial sidewall panel 422; a partial sidewall panel 424 and
a partial sidewall panel 426. The partial sidewall panel 424 and
the partial sidewall panel 426 may be integral with the partial
sidewall panel 422 and may be joined thereto by the fold lines 428
and 430. The insert member 420 has an upper edge 432. The insert
member 420 may, for example, be formed from the same material as
previously described with respect to the insert members 120 and
320. A latch mechanism 440 may be provided in the partial sidewall
panel 422 of the insert member 420 as shown. The latch mechanism
440 may generally be defined by an upper score line 441, a first
cut line 442 and a second cut line 444. A third cut line 450 may
extend across the latch mechanism 440 and intersecting both the
first and second cut lines 442, 444, as shown, dividing the latch
mechanism 440 into an upper (as viewed in FIG. 19) hinge portion
452 and a lower stationary portion 454. The cut lines 442, 444, 450
may extend completely through the material forming the insert
member 420 such that, together, the cut lines 442, 444, 450 will
form an opening 456 in the insert member 420 after the stationary
portion 454 is removed, as will be described in further detail
herein. A pair of uncut areas may be located within the cut line
450 forming retention tabs 446 and 448. A further retention tab 449
may be provided between the first and second cut lines 442, 444, as
shown. The retention tabs 446, 448, 449 serve to retain the
stationary portion 454 to the remainder of the hinge portion 452
and the remainder of the insert member 420 during manufacture of a
carton embodying the insert member 420.
[0053] The insert member 420 may be assembled into the carton blank
2 in substantially the same manner as previously described with
respect to the insert member 320. Specifically, when assembling the
insert member 420, adhesive 460, FIG. 20, may be supplied between
the insert member stationary portion 454 and the carton blank
sidewall panel 6, FIG. 2. In a manner similar to that described
with respect to the insert member 320, the rectangular sheet 140
may be secured to the insert member 420 around the periphery of the
latch mechanism 440 but not to the latch mechanism itself. Securing
the rectangular sheet 140 to the insert member 420 and to the
remainder of the carton blank 2 may be accomplished using a
conventional glue or by any other conventional mechanism.
[0054] After the insert member 420 has been attached to the carton
blank 2, as described above, the carton blank may be erected into a
carton 480 having a flip top lid 482, as illustrated in FIGS.
20-22. FIGS. 20-22, in a similar manner to FIGS. 16-18, illustrate
a sequence of operations through which the flip top lid 482 is
opened and then re-closed.
[0055] The carton 480 may be initially opened in generally the same
manner as the cartons 80 and 280, previously described.
Specifically, to initially open the carton 480, the opening tab
100, FIGS. 13 and 15, may be removed. The tab 108, e.g., FIG. 20,
may then be pulled upwardly, severing the outer layer of the carton
480 along the perforated lines 86 and 92, to the position
illustrated in FIG. 20. Referring now to FIG. 20, it can be seen
that the movement described above has also caused the stationary
portion 454 to separate from the insert member 420, due to the
adhesive 460 located between the flip top lid 482 and the
stationary portion 454 of the cutout portion 440. Specifically,
with reference to FIG. 19, the upward movement of the flip top lid
482 has caused the retention tabs 446, 448 and 449 to tear, thus
allowing the stationary portion 454 to completely separate from the
remainder of the insert member 420. Referring again to FIG. 20, the
upward movement of the flip top lid 482 also causes the hinge
portion 452 to bend about the score line 441. As can be appreciated
from FIG. 20, although separation of the stationary portion 454 and
bending of the hinge portion 452 about the score line 441 forms the
opening 456 through the insert member 420, the sheet 140 still
spans the opening 456.
[0056] FIG. 21 illustrates the flip top lid 482 in a further opened
condition. Referring to FIG. 21, it can be seen that the hinge
portion 452 maintains a nonaligned orientation with respect to the
remainder of the insert member partial sidewall panel 422. The
hinge portion 452 is biased toward this nonaligned orientation due
to the score line 441 and the bending action imposed on the hinge
portion 452 during opening of the lid 482, as illustrated in FIG.
20.
[0057] After the desired amount of product has been dispensed from
the open carton 480, the flip top lid 482 may be re-closed. This
re-closed condition is illustrated in FIG. 22. As can be seen from
FIG. 22, when the flip top lid is returned to its closed position,
the hinge portion 452 will engage above the upper edge of the
stationary portion 454. This engagement, in turn, causes the lid
482 to resist reopening and, thus, tends to maintain the lid in its
closed condition.
[0058] When it is desired to reopen the flip top lid 382, e.g., to
dispense further product from the container 480, the tab 108 may
again be pulled upwardly, thus causing the flip top lid 482 to once
again move through the sequence illustrated in FIGS. 20 and 21. As
can be appreciated from the above, the latch mechanism 440 serves
to maintain the flip top lid 482 in its closed position after the
lid has initially been opened.
[0059] As in the embodiment of FIGS. 13-18, the existence of the
sheet 140 in the vicinity of the opening 456 is advantageous in
that it seals the opening 46 and, thus, prevents product housed
withing the carton 480 from exiting the carton through the opening
456. Although the existence of the sheet 140 is beneficial in many
respects, the carton 480, like the carton 280, may, alternatively,
be manufactured without the sheet 140. In this case, a relatively
small section of material may be provided in order to cover the
opening 456. This small section of material may be attached, e.g.,
by gluing, to the partial sidewall panel 422 of the insert member
420, FIG. 19, in the vicinity of the opening 456. The small section
of material may, for example, be formed from the same material as
the sheet 140.
[0060] As in the embodiment of FIGS. 13-18, the stay closed feature
of FIGS. 19-22 is extremely advantageous in that it is easy to
manufacture. Specifically, the use of the latch mechanism 440 does
not require that any extra folds be provided in the insert member
420. Such folds add complexity when erecting a carton and it is,
thus, desirable to minimize them. Referring, for example, to FIG.
21, it can be seen that the hinge portion 452 is partially folded
about the score line 441. In other words, the hinge portion 452 is
non-aligned with the remainder of the partial sidewall panel 422 of
the insert member 420. This non-aligned configuration enables the
hinge portion 452 to spring into contact with the stationary
portion 454 when the flip top lid 482 is re-closed (see FIG. 22)
and, thus, is important to proper operation of the stay closed
feature. As can be appreciated with respect to FIG. 20, this
folding of the hinge portion 452 is caused by the opening of the
flip top lid 482. In other words, before the flip top lid is
initially opened, the hinge portion 452 is not folded about the
score line 441. Rather, the opening force supplied to the flip top
lid 482 by a user causes the folding to occur. Accordingly, the
fold does not have to be formed on the production line for forming
the carton 480. This, in turn, simplifies the carton forming
process.
[0061] The described stay closed feature is further extremely
advantageous in that no additional material is required in its
formation. Specifically, as described above, the latch mechanism
440, which includes the hinge portion 452, is removed from an
existing portion of the insert member 420. Accordingly, no
additional material is required to form the latch mechanism
440.
[0062] It is noted that, although the stay-closed feature of FIGS.
19-22 has been described in conjunction with the stay open feature
of FIGS. 1-12 for illustration purposes, it is to be understood
that either the stay closed feature or the stay open feature could,
alternatively, be used independently of each other. It is further
noted that, although, for illustration purposes, the stay closed
feature of FIGS. 19-22 is illustrated as being elliptical in shape,
it could, alternatively, be any other shape, such as rectangular or
round.
[0063] It is contemplated that the concepts herein described may be
variously otherwise embodied and it is intended that the appended
claims be construed to include alternative embodiments except
insofar as limited by the prior art.
* * * * *